Cutter body built with additive manufacturing
- October 17, 2019
Sandvik Coromant introduces the lightweight CoroMill 390, which features a cutter body produced using additive manufacturing.
The lighter overall weight of the tool helps to minimize vibration and improve security during machining with long overhang. In turn, the productivity is also increased, Sandvik says.
Additive manufacturing offers a superior way of producing complex structures with high precision and without joints. Use of the process can make components lighter, stronger and more flexible. With regard to tool bodies, additive manufacturing allows for the generation of shapes and features not possible with metal cutting. In addition, virtually any material can be printed, as in this case – a titanium alloy.
”When designing our new lightweight CoroMill 390, material has been tactically removed to create the optimal cutter design for minimizing mass,” explains Thomas Wikgren, manager, product application management, Sandvik Coromant. “This is called topological optimization and it makes the cutter more compact and significantly lighter than a conventional version, thus helping machine shops to boost the productivity of their long-overhang milling operations. Moreover, a shorter distance between the damper in the adaptor and the cutting edge improves performance and process security.”
Process security is paramount in a number of metal-cutting applications, not least when milling with long overhangs, which is a common requirement in components used by the aerospace and oil and gas sectors. Here, the generation of features such as deep cavities can be compromised by vibration, leading to slower production, shorter tool life and poor surface finish.
The CoroMill 390, combined with Silent Tools milling adaptors, minimizes vibration to enhance productivity and process security in applications involving long overhangs. The concept also delivers lighter cutting action.
Sandvik says the CoroMill 390 can perform long-reach face milling, deep shoulder and side milling, cavity milling, and slot milling. The tool is available in 40 mm (1.57 in.: arbor 16 coupling) and 50 mm (1.97 in.: arbor 22 coupling) diameter variants. Three or four inserts (size 11) can be specified to suit the application. Differential pitch and internal coolant are provided on all cutters.